Dimensionally-Stabilized Cushioned Carpet Tile and Methods of Manufacture Thereof

Abstract

A carpet tile is provided that includes a face fabric having a top surface and a base, and a dimensionally-stabilized non-woven cushion material having a stabilizing material incorporated therein, incorporated thereonto or a combination thereof. The dimensionally-stabilized non-woven cushion material may be attached to the face fabric such that the dimensionally-stabilized non-woven cushion material provides dimensional stability to the face fabric. Methods of manufacturing dimensionally-stabilized cushioned carpet tile are also provided.

1 . A carpet tile comprising:
 a face fabric having a top surface and a base; and   a dimensionally-stabilized non-woven cushion material having a stabilizing material incorporated therein, incorporated thereonto, or a combination thereof, wherein the dimensionally-stabilized non-woven cushion material is attached to the base if the face fabric such that the dimensionally-stabilized non-woven cushion material provides dimensional stability to the face fabric.   
     
     
         2 . The carpet tile of  claim 1 , wherein the stabilizing material comprises non-woven PET, polyamide, polypropylene or a blend thereof. 
     
     
         3 . The carpet tile of  claim 1 , wherein the cushion material comprises a needle-punched fiber pad. 
     
     
         4 . The carpet tile of  claim 1 , wherein the stabilizing material is arranged in regular or irregular patterns throughout the non-woven fiber pad. 
     
     
         5 . The carpet tile of  claim 1 , wherein the dimensionally-stabilized non-woven cushion provides sufficient dimensional stability to prevent shrinkage, growth, or curling of the carpet tile. 
     
     
         6 . The carpet tile of  claim 1 , wherein the dimensionally-stabilized non-woven cushion provides sufficient dimensional stability to prevent shrinkage, growth, or curling of the carpet tile without requiring the use of additional stabilizing material. 
     
     
         7 . A carpet tile comprising:
 a primary carpet base having a face fabric side and an opposed back side;   a polymer adhesive layer attached to the back side of the primary carpet base; and   a dimensionally stabilized non-woven cushion material layer attached to the primary carpet base by the polymer adhesive layer, the dimensionally stabilized non-woven cushion material having a stabilizing material incorporated therein, incorporated thereonto, or a combination thereof.   
     
     
         8 . The carpet tile of  claim 7 , wherein the stabilizing material comprises non-woven PET, polyamide, polypropylene or a blend thereof. 
     
     
         9 . The carpet tile of  claim 7 , wherein the cushion material comprises a needle-punched fiber pad. 
     
     
         10 . The carpet tile of  claim 7 , wherein the stabilizing material is arranged in regular or irregular patterns throughout the non-woven fiber pad. 
     
     
         11 . The carpet tile of  claim 7 , wherein the dimensionally-stabilized non-woven cushion provides sufficient dimensional stability to prevent shrinkage, growth, or curling of the carpet tile. 
     
     
         12 . The carpet tile of  claim 7 , wherein the dimensionally-stabilized non-woven cushion provides sufficient dimensional stability to prevent shrinkage, growth, or curling of the carpet tile without requiring the use of additional stabilizing material. 
     
     
         13 . A method of manufacturing a carpet tile comprising:
 integrating a stabilizing material with a cushion material to form a dimensionally-stabilized cushion material; and   attaching the dimensionally-stabilized cushion material to a face fabric.   
     
     
         14 . The method of  claim 13 , wherein the cushion material is attached to the face fabric with a polymer adhesive. 
     
     
         15 . The method of  claim 13 , wherein the stabilizing material is incorporated into the cushion material before the cushion material is attached to the face fabric. 
     
     
         16 . The method of  claim 13 , wherein the stabilizing material comprises non-woven PET, polyamide, polypropylene, or a blend thereof. 
     
     
         17 . The method of  claim 13 , wherein the cushion material comprising a needle-punched fiber pad, a spunbound fiber pad, a fusion-bonded fiber pad, or a combination thereof. 
     
     
         18 . The method of  claim 13 , wherein stabilizing material is integrated with the stabilizing material by needle-punching, spunbounding, or fusion-bonding. 
     
     
         19 . A carpet tile produced by the method of  claim 13 . 
     
     
         20 . A method of manufacturing a carpet tile comprising:
 producing a face fabric comprising a plurality of pile extending from a primary carpet base;   producing a dimensionally-stabilized cushion pad comprising a non-woven cushion material and a stabilizing material incorporated therewith;   laminating the dimensionally-stabilized cushion pad to the face fabric with a polymer adhesive; and   curing the polymer adhesive such that it locks the plurality of pile to the primary carpet base and bonds the dimensionally-stabilized cushion pad to the face fabric.